Particulate Materials for Acoustic Texture Material

ABSTRACT

An acoustic texture material adapted to be dispensed from an aerosol assembly using bi-phase propellant materials to form a textured coating on drywall material such that the textured coating substantially matches a pre-existing acoustic texture material on the drywall material. The acoustic texture material has a base portion capable of existing in a flowable state and a hardened state and a particulate portion comprising discrete particles that are visible to an unaided eye. The particulate portion is comprised of at least one of urethane foam and melamine foam. The base portion is capable of securing the particles to the drywall material when the base portion is in the hardened state.

RELATED APPLICATIONS

This application, (Attorney's Ref. No. P217346) is a continuation ofU.S. patent application Ser. No.13/114,954 filed May 24, 2011.

U.S. patent application Ser. No. 13/114,954 is a continuation of U.S.patent application Ser. No. 11/982,134 filed Oct. 31, 2007, now U.S.Pat. No. 7,947,753 which issued May 24, 2011.

U.S. patent application Ser. No. 11/982,134 is a continuation of U.S.patent application Ser. No. 11/027,219 filed Dec. 29, 2004, now U.S.Pat. No. 7,374,068 which issued May 20, 2008.

U.S. patent application Ser. No. 11/027,219 claims benefit of U.S.Provisional Patent Application Ser. No. 60/617,236 filed Oct. 8, 2004.

All related applications cited in this Related Applications section,including the subject matter thereof, are incorporated herein byreference.

TECHNICAL FIELD

The present invention relates to particulate materials for use inacoustic texture material and, more particularly, to particulatematerials that may be used in acoustic texture material formulated to bedispensed from aerosol dispensers.

BACKGROUND

Interior walls are formed by sheets of drywall material that are securedto the framing of a building. The seams between adjacent sheets ofdrywall material are taped, mudded, and sanded to obtain a substantiallyflat, smooth drywall surface. The drywall surface is coated with primerand paint to obtain a finished surface.

In some situations, a separate texture layer is applied to the drywallsurface prior to painting. The texture layer is formed by sprayingtexture material onto the drywall surface. Texture material is a coatingmaterial that, when sprayed, does not form a smooth, thin coating.Instead, texture material is applied in discrete drops or globs that dryto form a bumpy, irregular textured surface.

Texture materials can be applied using any one of a number ofapplication systems. During new construction, texture materials arecommonly applied in a stream of compressed air using commercial hoppergun systems. For touch up or repair, texture material is commonlyapplied using hand operated pneumatic pumps or aerosol dispensingsystems. Varying the parameters of the application system varies thesize and spacing of the bumps to vary the look of the textured surface.

One specific form of texture material is commonly referred to as“acoustic” or “popcorn” texture material. In addition to a coatingmaterial, acoustic texture material further comprises an aggregatematerial. When the acoustic texture material is applied using commercialhopper guns, the aggregate material is conventionally formed bypolystyrene chips. However, as will be described in detail below, chipsmade of polystyrene foam are dissolved by hydrocarbon aerosol propellantmaterials.

Accordingly, aerosol dispensing systems for dispensing small amounts ofacoustic texture material for repair or touch-up purposes use one of twoapproaches. The first approach is to mix a liquid hydrocarbon aerosolpropellant material with chips made from materials other thanpolystyrene. However, when chips made of materials other thanpolystyrene foam are used, the appearance and function of the texturesurface may be different from that of the surrounding surface.

The second approach is to combine polystyrene chips with a propellantmaterial formed by a pressurized inert gas such as nitrogen or air. Thissecond approach allows the use of a conventional acoustic texturematerial including polystyrene chips. However, the use of a pressurizedinert gas causes the acoustic texture material to be dispensed veryquickly. The use of pressurized inert gas as a propellant can make itdifficult for a non-professional to control the application of theacoustic texture material.

The need thus exists for improved systems and methods for dispensingsmall quantities of acoustic texture material for the purpose oftouch-up or repair.

SUMMARY

The present invention may be embodied as an acoustic texture materialadapted to be dispensed from an aerosol assembly using bi-phasepropellant materials to form a textured coating on drywall material suchthat the textured coating substantially matches a pre-existing acoustictexture material on the drywall material. The acoustic texture materialhas a base portion capable of existing in a flowable state and ahardened state and a particulate portion comprising discrete particlesthat are visible to an unaided eye. The particulate portion is comprisedof at least one of urethane foam and melamine foam. The base portion iscapable of securing the particles to the drywall material when the baseportion is in the hardened state.

The present invention may also be embodied as a method of using anaerosol assembly to form a textured coating on a drywall material suchthat the textured coating substantially matches a pre-existing acousticcoating on the drywall material comprising the following steps. A baseportion is provided in a flowable state. A particulate portioncomprising discrete particles of at least one of urethane foam andmelamine foam is provided. The discrete particles are visible to theunaided eye. A bi-phase propellant material formulated not to dissolvethe discrete particles is provided. The base portion in the flowablestate, the particulate portion, and the bi-phase propellant are arrangedwithin the aerosol assembly. The aerosol assembly is operated such thata portion of the bi-phase propellant material forces the base portion inthe flowable state and the particulate portion out of the aerosolassembly and onto the drywall material. The base portion is allowed toform a hardened state in which the base portion secures the discreteparticles to the drywall material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a section view of a first embodiment of an aerosol dispensingsystem containing acoustic texture material incorporating particulatematerial of the present invention;

FIG. 2 is a section view of a second embodiment of an aerosol dispensingsystem containing acoustic texture material incorporating particulatematerial of the present invention;

FIG. 3 is an elevation view depicting the use of one or both of thefirst and second aerosol dispensing systems of FIGS. 1 and 2 being usedto deposit acoustic texture material to a surface;

FIG. 4 is a section view of the acoustic texture material after it hasbeen deposited on the surface; and

FIGS. 5 and 6 are bottom plan views of the surface before and after theacoustic texture material has been deposited thereon.

DETAILED DESCRIPTION

Referring initially to FIG. 1 of the drawing, depicted at 20 a thereinis a first embodiment of an aerosol system for depositing on a surface22 (FIGS. 3-6) acoustic texture material 24 incorporating particulatematerial 26 of the present invention. FIG. 5 illustrates a targetportion 28 of the surface 22 on which acoustic texture material 24 is tobe deposited.

The example aerosol system 20 a comprises a container assembly 30, avalve assembly 32, a collection assembly 34, and an outlet assembly 36.The container 30 defines a product chamber 40 in which the acoustictexture material 24 comprising the particulate material 26 is contained.A first portion 42 of the chamber 40 is occupied by the acoustic texturematerial 24, while a second portion 44 of the chamber 40 is occupied bya pressurized propellant material 46. The example container assembly 30comprises a can member 50 and a cup member 52.

The valve assembly 32 is mounted in a cup opening 34 define by the cupmember 52 and operates in a closed configuration (shown) and an openconfiguration. In the open configuration, the valve assembly 32 definesa dispensing passageway that allows fluid communication between theinterior and the exterior of the container assembly 30.

The outlet assembly 36 comprises an actuator member 60 that causesacoustic texture material 24 to be dispensed by the system 20 in a fanshaped spray as will be described in further detail below. The actuatormember 60 is mounted on the valve assembly 32 such that displacing theoutlet member 60 towards the valve assembly 32 places the valve assemblyin the open configuration.

The example valve assembly 32 comprises a valve seat 70, a valve stem72, a valve housing 74, a dip tube 76, and a valve spring 78. The valveseat 70 defines a seat opening 70 a and is supported by the cup member52. The valve stem 72 defines a valve stem opening 72 a and a valvesurface 72 b. The valve stem 72 is supported by the valve seat 70 suchthat the valve stem moves within the valve stem opening 72 a betweenfirst and second positions, with the first position being shown in FIG.1.

The valve housing 74 is supported by the valve seat 70 within theproduct chamber 40. The valve housing 74 further supports the dip tube76 such that the acoustic texture material 24 within can flow into thevalve housing 74 when the can is upright. The valve spring 78 issupported by the valve housing 74 such that the spring 78 biases thevalve stem 72 into the first position. The valve stem 72 supports theoutlet assembly 36 such that depressing the actuator member 60 towardsthe cup member 52 forces the valve stem 72 into the second position (notshown) against the force of the valve spring 78.

The valve assembly 32 thus operates in the closed configuration and theopen configuration as follows. When no force is applied to the actuatormember 60, the valve spring 78 forces the valve surface 72 b against thevalve seat 70 to prevent fluid from flowing through the valve stemopening 72 a. When a force is applied to the actuator member 60, thevalve surface 72 b is forced away from the valve seat 70 such that fluidcan flow from the interior of the valve housing 74 through the valvestem opening 72 a and thus out of the product chamber 40.

Referring now to FIG. 2 of the drawing, depicted at 20 b therein is afirst embodiment of an aerosol system that may also be used to depositthe acoustic texture material 24 incorporating particulate material 26of the present invention on the target portion 28 of the surface 22.

The example aerosol system 20 b comprises a container assembly 130, avalve assembly 132, a collection assembly 134, and an outlet assembly136. The container 130 defines a product chamber 140 in which theacoustic texture material 24 comprising the particulate material 26 iscontained. A first portion 142 of the chamber 140 is occupied by theacoustic texture material 24, while a second portion 144 of the chamber140 is occupied by a pressurized propellant material 146. The examplecontainer assembly 130 comprises a can member 150 and a cup member 152.

The valve assembly 132 is mounted in a cup opening 134 define by the cupmember 152 and operates in a closed configuration (shown) and an openconfiguration. In the open configuration, the valve assembly 132 definesa dispensing passageway that allows fluid communication between theinterior and the exterior of the container assembly 130.

The outlet assembly 136 comprises an actuator member 160 that causesacoustic texture material 24 to be dispensed by the system 20 in a fanshaped spray as will be described in further detail below. The actuatormember 160 is mounted on the valve assembly 132 such that displacing theoutlet member 160 towards the valve assembly 132 places the valveassembly in the open configuration.

The example valve assembly 132 comprises a valve seat 170, a valve stem172, a valve housing 174, a dip tube 176, and a valve spring 178. Thevalve seat 170 defines a seat opening 170 a and is supported by the cupmember 152. The valve stem 172 defines a valve stem opening 172 a and avalve surface 172 b. The valve stem 172 is supported by the valve seat170 such that the valve stem moves within the valve stem opening 172 abetween first and second positions, with the first position being shownin FIG. 1.

The valve housing 174 is supported by the valve seat 170 within theproduct chamber 140. The valve housing 174 further supports the dip tube176 such that the acoustic texture material 124 within can flow into thevalve housing 174 when the can is upright. The valve spring 178 issupported by the valve housing 174 such that the spring 178 biases thevalve stem 172 into the first position. The valve stem 172 supports theoutlet assembly 136 such that depressing the actuator member 160 towardsthe cup member 152 forces the valve stem 172 into the second position(not shown) against the force of the valve spring 178.

The valve assembly 132 thus operates in the closed configuration and theopen configuration as follows. When no force is applied to the actuatormember 160, the valve spring 178 forces the valve surface 172 b againstthe valve seat 170 to prevent fluid from flowing through the valve stemopening 172 a. When a force is applied to the actuator member 160, thevalve surface 172 b is forced away from the valve seat 170 such thatfluid can flow from the interior of the valve housing 174 through thevalve stem opening 172 a and thus out of the product chamber 140.

Turning now to FIGS. 3-6, the use of the aerosol dispensing systems 20 aand 20 b will now be described in further detail. These dispensingsystems 20 a and 20 b are used in the same manner and are bothidentified by reference character 20 in FIGS. 3-6.

As shown in FIG. 3, the dispensing system 20 deposits a fan-shaped sprayof acoustic texture material 24 on the target portion 28 of the wall 22.As shown in FIGS. 4 and 6, the acoustic texture material 24 covers thetarget portion 28 to match the pre-existing acoustic texture material onthe surface 22 surrounding the target portion 28.

Referring for a moment back to FIGS. 1 and 2, it can be seen that, inaddition to the particulate material 26, the acoustic texture materialcomprises a base portion 220 in the form of a flowable liquid. The baseportion 220 of the particulate material conventionally comprises acarrier, a filler, and a binder.

In some aerosol systems, the propellant material 46,146 is simply aninert pressurized gas such as air or nitrogen. In other aerosol systems,the propellant material 46,146 is a material, referred to herein asbi-phase propellant material, that exists in both gaseous and liquidphases within the container assembly 30,130. The liquid phase of thepropellant material 46,146 forms a part of the base portion 220, whilethe gaseous phase propellant material 46,146 occupies the pressurizedportion 44 of the container assembly 30,130.

As the acoustic texture material 24 is dispensed, the pressure withinthe pressurized portion 44,144 of the container assemblies 30,130 drops.Under these conditions, a portion of the bi-phase propellant material46,146 in the liquid phase gasifies to re-pressurize the pressurizedportion 44,144 of the container assembly 30,130. The pressure within thepressurized portion 44,144 is thus under most conditions sufficient toforce the acoustic texture material 24 out of the container assembly30,130 along the dispensing passageway when the valve assembly 32,132 isin the open configuration. The propellant material 46,146 may thus be apressurized inert gas such as air or nitrogen.

However, the present invention is of particular significance when thepropellant material is a bi-phase propellant material such as di-methylethylene (DME) or any one of a number of hydrocarbon propellants such asthose available in the industry as A-40 and A-70. The advantage of usingbi-phase propellant materials is that the pressure within thepressurized portion 44,144 of the container assembly 30,130 is kept at arelatively constant, relatively low level as the level of acoustictexture material 24 drops. This constant, low level pressure allows thetexture material 24 to be dispensed in many small bursts instead of in afew large bursts, as is the case when pressurized inert gases are usedas the propellant material 46,146.

Many particulate materials 26 suitable for use in acoustic texturematerials are incompatible with bi-phase propellant materials. Forexample, as described above polystyrene chips are commonly used inacoustic texture materials dispensed using commercial hopper guns.However, polystyrene chips dissolve in the bi-phase propellant materialsof which the Applicant is aware.

The Applicant has discovered that urethane foam materials and melaminefoam materials may be used as the particulate material 26 with bi-phasepropellant materials such as DME and hydrocarbon propellants such asA-40 and A-70. Melamine foam materials in particular are easily choppedup using conventional material processors (e.g., a food blender) intoirregular shapes that match the appearance and function of polystyrenechips. Melamine foam materials are already commonly used in buildingapplications and have desirable fire retardant, thermal, and acousticproperties.

To manufacture the acoustic texture material 24, the base portion 220may be the same as a conventional base used in commercially availableacoustic texture materials. Instead of polystyrene chips, however,urethane and/or melamine foam is chopped up into particles of anappropriate size and use as the particulate. In addition, a bi-phasepropellant material is used to form part of the carrier portion of thebase portion 220.

The Applicant has thus determined that a conventional base portion usingmelamine foam chips and DME as a propellant is commercially practicaland obtains acceptable aesthetic and functional results. Appropriateadjustments in the liquids used as the carrier in a conventionalacoustic texture material formulation may be required to obtain adesired consistency of the acoustic texture material 24 as it isdeposited on the surface 22.

What is claimed is:
 1. An acoustic texture material adapted to bedispensed from an aerosol assembly using bi-phase propellant materialsto form a textured coating on drywall material such that the texturedcoating substantially matches a pre-existing acoustic texture materialon the drywall material, the acoustic texture material comprising: abase portion capable of existing in a flowable state and a hardenedstate; and a particulate portion comprising discrete particles that arevisible to an unaided eye; wherein the particulate portion is comprisedof at least one of urethane foam and melamine foam; and the base portionis capable of securing the particles to the drywall material when thebase portion is in the hardened state.
 2. An acoustic texture materialas recited in claim 1, in which the particulate portion is formulatedsuch that the bi-phase propellant materials do not dissolve thediscrete, visible, irregular particles when the acoustic texturematerial is mixed with a liquid phase of the bi-phase propellantmaterials.
 3. An acoustic texture material as recited in claim 1, inwhich the particulate portion is distributed throughout the base portionwhen the base portion is in the flowable state and the acoustic texturematerial is stored within the aerosol assembly.
 4. A method of using anaerosol assembly to form a textured coating on a drywall material suchthat the textured coating substantially matches a pre-existing acousticcoating on the drywall material comprising the steps of: providing abase portion in a flowable state; forming a particulate portioncomprising discrete particles of at least one of urethane foam andmelamine foam, where the discrete particles are visible to the unaidedeye; providing a bi-phase propellant material formulated not to dissolvethe discrete particles; arranging the base portion in the flowablestate, the particulate portion, and the bi-phase propellant within theaerosol assembly; operating the aerosol assembly such that a portion ofthe bi-phase propellant material forces the base portion in the flowablestate and the particulate portion out of the aerosol assembly and ontothe drywall material; allowing the base portion to form a hardened statein which the base portion secures the discrete particles to the drywallmaterial.
 5. A method as recited in claim 4, further comprising the stepof formulating the particulate portion such that the bi-phase propellantmaterials do not dissolve the particles when the acoustic texturematerial is mixed with the bi-phase propellant materials.
 6. A method asrecited in claim 4, further comprising the step of distributing theparticulate portion throughout the base portion when the base portion isin the flowable state and the acoustic texture material is within theaerosol assembly.